CN113202253A - Panel for forming a floor covering and such a floor covering - Google Patents

Panel for forming a floor covering and such a floor covering Download PDF

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Publication number
CN113202253A
CN113202253A CN202010661689.8A CN202010661689A CN113202253A CN 113202253 A CN113202253 A CN 113202253A CN 202010661689 A CN202010661689 A CN 202010661689A CN 113202253 A CN113202253 A CN 113202253A
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CN
China
Prior art keywords
panel according
panel
magnesium
core layer
layer
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CN202010661689.8A
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Chinese (zh)
Inventor
托马斯·卢克·马丁·贝尔特
汤姆·范·波尔
斯万·伯恩
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Chinafloors Timber China Co ltd
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Chinafloors Timber China Co ltd
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Publication of CN113202253A publication Critical patent/CN113202253A/en
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02044—Separate elements for fastening to an underlayer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/10—Lime cements or magnesium oxide cements
    • C04B28/105—Magnesium oxide or magnesium carbonate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/30—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/30—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
    • C04B28/32—Magnesium oxychloride cements, e.g. Sorel cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206—Layered panels for sound insulation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/12—Mixture of at least two particles made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/20—Particles characterised by shape
    • B32B2264/204—Rod- or needle-shaped particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/30—Particles characterised by physical dimension
    • B32B2264/302—Average diameter in the range from 100 nm to 1000 nm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/30—Particles characterised by physical dimension
    • B32B2264/304—Particle length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0153—Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)
  • Finishing Walls (AREA)

Abstract

The present invention relates to a panel suitable for forming a floor covering, in particular a floor panel, wherein the panel has a substantially flat top side and a substantially flat bottom side, and at least four substantially linear side edges comprising at least one pair of opposite side edges, said side edges preferably being provided with locking means.

Description

Panel for forming a floor covering and such a floor covering
Technical Field
The present invention relates to panels, in particular floor panels, suitable for forming floor coverings. The invention also relates to such floor covering.
Background
The flooring industry typically uses generally conventional materials for making (laminated) floor tiles. Examples of such materials are: high Density Fiberboard (HDF), which may be consolidated together by formaldehyde or phenolic resin; heterogeneous or homogeneous polyvinyl chloride (PVC), which may contain any plasticizers, solid hardwood sheets; a plurality of thin plates glued together; and fired glazed clays, such as ceramics and ceramic tiles. The purpose for which these materials are used depends mainly on their material properties, such as impact resistance, rigidity, acoustic properties and/or appearance. However, interest has arisen in recent years in the use of alternative materials. An example of this is the use of mineral materials, since mineral materials generally have a relatively high dimensional stability and sufficient heat resistance and have a small environmental impact compared to conventional materials (e.g. PVC or HDF). However, it is not particularly suitable for use as a component of floor panels as its development has focused on use as a building material, particularly as a replacement for gypsum/drywall. It is desirable, among other features, that panels made from such mineral materials have improved flexural strength, impact resistance, indentation resistance, cohesion and surface adhesion, making them suitable for use as components of floor panels.
Disclosure of Invention
It is an object of the present invention to provide at least one alternative embodiment of a composite mineral panel, in particular a floor panel, which has competitive material properties with respect to the prior art.
To this end, the invention provides a panel, in particular a floor panel, suitable for forming a floor covering, wherein the panel has a substantially flat top side and a substantially flat bottom side, and at least four substantially linear side edges comprising at least one pair of opposite side edges, the panel comprising at least one core layer, said at least one core layer at least partially comprising a magnesium crystal structure, wherein said at least one core layer comprises at least one organic compound, said at least one organic compound comprising at least two hydroxyl groups; preferably wherein the organic compound is present in a range of 0.05% to 5% by weight.
The core layer comprises at least in part a magnesium crystal structure comprising at least one organic compound comprising at least two hydroxyl groups; preferably wherein the organic compound is present in the range of 0.05 to 5 weight percent, resulting in an increased amount of advantageous whisker or needle-like shaped crystals in the crystal structure compared to platelet-like or irregularly shaped crystals.
The invention therefore also relates to a panel suitable for forming a floor covering, in particular a floor panel, wherein the panel has a substantially flat top side and a substantially flat bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges; the panel includes a core layer comprising a magnesium oxide binder, wherein the magnesium oxide binder comprises magnesium oxide crystals in a flake or irregular shape and in a whisker or needle shape, wherein the whisker or needle shape crystals are more numerous than the flake or irregular shape crystals.
The core layer comprising at least one core layer comprising magnesium crystal structures (e.g. magnesium oxysulphate whiskers, which at least partially form a dense crystal microstructure) provides the panel with a significant improvement of cohesion combined with good impact resistance and good bending strength. This results in panels that are particularly suitable for flooring applications. The magnesium crystal structure includes magnesium crystals, preferably magnesium oxysulfate crystals.
In particular, the core layer includes a magnesium oxide adhesive. The formation and microstructure of a magnesium oxide binder can be described by the "crystalline" or "hydrated" phase and is represented by a ternary system consisting of proportions of magnesium oxide, magnesium salt (such as magnesium sulfate or magnesium chloride) and water. The crystalline phases form, after solidification, ceramic compounds and can be represented in abbreviated form, referring to the molar ratio of each in the crystals formed. The magnesium oxysulfate adhesive taking magnesium sulfate salt as a main binding material can form two stable crystal phases under the environmental condition; one of them consists of the compound magnesium oxide, magnesium sulfate and water, generally referred to as the 5 phase (also referred to as the 5-1-3 phase, representing 5Mg (OH))2.MgSO4.3H2O) and 3 phases (also referred to as 3-1-8 phases, representing 3Mg (OH)2.MgSO4.8H2O). The former exhibits a beneficial acicular or whisker-like crystal structure with a diameter of 0.2-1.0 μm and a length20-50 μm, has good bending strength, while the latter exhibits a flaky or irregular crystal shape, resulting in a weaker composition. When referring to a magnesium oxysulfate binder intended for use under favorable conditions, it is intended to refer to a ceramic composition comprising a crystal phase structure of 5-1-3 phase magnesium oxysulfate whiskers or a crystal phase structure of 3-1-8 phase magnesium oxysulfate flakes. The "lamellar" structure of 3-1-8 is generally considered to be a more stable phase structure at 20-60 ℃ and in the presence of a pleasant atmosphere. Other phases may form at extreme pressures and temperatures, but are unstable at the temperatures of habitability. When preparing the magnesium oxysulfate adhesive, naturally, at least 50% of the composition consists of 3-1-8 crystals. Its flaky or irregular structure leads to weathering of the panel surface, with consequent poor cohesion and low surface adhesion, which makes it particularly unsuitable for use as a component in a floor panel.
The present invention provides a floor panel comprising at least one core layer having a ratio of magnesium oxysulfate 5-1-3 "whisker" phase to 3-1-8 "platelet" phase of greater than 1.
The magnesium oxysulfate whiskers have the advantage of being formed under ambient conditions. The magnesium oxysulfate whiskers may also be referred to as crystal needles. Since the magnesium oxysulfate whiskers at least partially form a crystalline structure, the magnesium oxysulfate whiskers will interlock with one another to form a high density microstructure. These interlocking whiskers thereby provide improved strength to the core layer of the panel. In addition, the panel according to the invention is advantageous due to the presence of said core layer having good impact resistance; this is advantageous, for example, when applying a plurality of panels in the floor covering according to the invention. The compression and indentation resistance of the crystal structure of the 5-1-3 phase was higher than 50MPa, while the compression and indentation resistance of the 3-1-8 structure was only about 20MPa when tested according to EN 310. The panels of the invention also have good water and moisture resistance, since the whiskers are not readily soluble in water, whereas the 3-1-8 phases are less stable under wet conditions.
Magnesium oxysulfate whiskers are not obvious materials for use in the core material object of the present invention and for forming the crystal structure to a person skilled in the art. The skilled person will generally use the more common ones and may form(oxy) magnesium chloride binder in crystalline phase, in which the magnesium chloride whiskers can range from 5-1 to 8(5Mg (OH)2.MgCl2.8H2O phase and/or 3-1-8(3Mg (OH))2.MgCl2.8H2O) phase is present. However, these magnesium chloride crystals are relatively water-insoluble, as water can leach out soluble magnesium chloride, which can result in a significant reduction in material strength. The magnesium oxysulfate whiskers do not have this disadvantage. As an alternative to providing other additives to improve the material properties, the present invention provides different materials. However, it is not excluded that the floor panel according to the invention comprises a relatively small proportion of magnesium chloride, for example at most 5% by weight, preferably less than 1% by weight.
The magnesium oxysulfate whiskers may be prepared by mixing a reactive magnesium oxide with an aqueous solution of magnesium sulfate. The reactive magnesium oxide may be obtained by a calcination process carried out at a temperature in the range of 600 to 1300 degrees celsius, preferably in the range of 800 to 1000 degrees celsius. The reactive magnesium oxide (RM) may also be referred to as "caustic calcined magnesium oxide (CCM)" or light calcined magnesium oxide.
The first condition for forming the desired MOS whisker is the proportion of raw materials. By mixing MgSO 24Mixing with water at a ratio of 0.6-2: 1 to prepare an aqueous solution of magnesium salt which is stirred for about 2 minutes to dissolve it, so that the mixture forms a ceramic material during solidification. To ensure that the ratio of whisker to platelet phases is greater than 1, MgO to MgSO4Should be kept in the range of 4.6 to 5.8: about 1, preferably 4.9 to 5.2. A second condition for forming the desired crystal structure is to add to the slurry a second aqueous solution of 0.05 to 10% by weight, the second aqueous solution comprising 50 to 90% by weight of an organic compound comprising at least two hydroxyl groups (-OH). This includes functional groups comprising hydroxyl groups (e.g., carboxyl (-COOH)) that have the same effect on the formation of MOS whisker crystals. Best results are obtained with dicarboxylic acids containing two carboxyl functions-COOH, most advantageously of short chain length, for example oxalic acid C2H2O4(two carboxyl-COOH groups) or mesoxalic acid C3H2O5(two to four Carboxylic acids based on the Presence of WaterA group-COOH group)). Citric acid C6H8O7(four-OH hydroxyl groups) and boronic acid H3BO3Good results were also obtained with (three-OH hydroxyl groups). It has been found that the addition of at least a part of these elements affects the crystal structure of the core layer and increases and enhances the crystallization of MgO into a preferred crystalline phase, which is advantageous for foreseeable use as floor panels. Phosphoric acid is also contemplated.
The ceramic material or mixture of ceramic binder and additives is poured into a mold and allowed to set at ambient or elevated temperature until cured. The cured material has good strength and good flame retardant properties, which makes the material particularly suitable for use in the construction industry. However, it is also possible to produce magnesium oxysulfate whiskers from magnesium sulfate and magnesium hydroxide by hydrothermal synthesis.
The panel according to the invention typically has a core layer with a thickness in the range of 3 to 10 mm. The density of the core layer is generally 1200-1500kg/m3More specifically 1300-3Left and right. An embodiment of the invention may consist of a multilayer magnesium oxysulfate adhesive, wherein each layer has a specific crystal structure, advantageously at least the ratio of 5-1-3MOS whisker phase to 3-1-8MOS whisker phase in the top layer is larger than 1, or the top layer and the bottom layer have a similar ratio, or essentially the entire core layer consists of such a similar ratio, depending on the specific requirements of the floor panel in question. It should be understood that in one embodiment, different layers of the core may have different crystal structure ratios to enhance acoustic performance.
The panel has a substantially flat top side and a substantially flat bottom side, and at least four substantially linear side edges including at least one pair of opposing side edges. The panels are typically substantially rectangular or square. However, it is also conceivable that the panels have a substantially parallelogram shape. When referring to a panel, it can be either a floor panel or a wall panel. The term "tile" is interchangeable with the term "panel".
The aspect ratio of at least a plurality of the magnesium oxysulfate whiskers is generally at least 5, preferably at least 10, more preferably at least 20. In such embodiments, the magnesium oxysulfate whiskers may provide sufficient (flexural) strength to the core layer of the panel. Possibly, at least some of the magnesium oxysulfate whiskers have an average diameter in a range from 0.2 to 1.0 microns and/or at least some of the magnesium oxysulfate whiskers have an average length in a range from 1 to 50 microns. The exact shape of the magnesium oxysulfate whiskers may vary due to the phase at which the magnesium oxysulfate whiskers are stable at a given temperature and humidity.
The magnesium oxysulfate whiskers in the core layer are not required to form a crystal structure over substantially the entire core layer. Indeed, in a preferred embodiment, the core layer comprises at least 50%, preferably at least 55%, more preferably at least 60% by weight of magnesium oxysulphate whiskers in the crystal structure of the whisker phase. The other volume of the core layer may have an amorphous structure. Another volume of the core layer may for example be at least partially porous. In some embodiments, it is advantageous if a portion of the core layer comprises a crystal structure of magnesium oxysulfate whiskers in an amount less than 50% by weight. A higher percentage may result in a reduction of the mechanical strength of the core layer and thus of the panel.
In a possible embodiment, the core layer comprises an upper portion and a lower portion and a reinforcement layer located between said upper portion and said lower portion of the core layer. The upper part of the core layer may even define a substantially flat top side and the bottom part of the core layer may define a substantially flat bottom side of the panel. The presence of the at least one reinforcing layer may result in an improvement of the acoustic properties of the panel. This may result in improved sound attenuation characteristics, for example. The presence of at least one reinforcing layer may also contribute to an increased strength of the panel itself. The reinforcing layer may, for example, comprise a woven or non-woven fibrous material. In an advantageous embodiment, the reinforcement layer may comprise glass fibers. The reinforcing layer may in particular comprise a glass fibre mesh. Non-limiting examples thereof are glass fiber webs having a mesh size of at least 5 x 5mm and/or having a mesh size of at least 90g/m2Area weight of glass fiber web. In a possible embodiment, the glass fiber web may be provided with a coating to prevent skin reactions during physical contact. It is contemplated that the thickness of the reinforcing layer is about 0.2 to 0.4 mmAnd (4) rice.
In another possible embodiment, the core layer further comprises a middle portion and a further reinforcing layer, wherein the first reinforcing layer is located between said upper portion and said middle portion of the core layer and the second reinforcing layer is located between said middle portion and said lower portion of said core layer. Both the first reinforcing layer and the second reinforcing layer may be composed of the reinforcing layers as described above. The central portion of the core layer does not necessarily have to have the same material properties as the other portions of the core layer. For example, it is conceivable for the central part of the core layer to be at least partially foamed. Thus, the central portion may contain a blowing agent. Such an at least partially foamed middle portion of the core layer may further improve the acoustic properties of the panel.
In a preferred embodiment, the panel comprises two pairs of opposite side edges provided with interconnecting coupling means. This will help to easily connect a plurality of panels when assembling e.g. a floor covering. Interconnected coupling devices typically include a tongue disposed on one of a pair of opposing side edges and a groove disposed on the other of the same pair of opposing side edges. The mutually interconnecting coupling means of the co-acting panels may be provided with co-acting locking elements.
In a possible embodiment of the panel according to the invention, the core layer further comprises at least one polymer and/or wood based material. It is also conceivable that the core layer also comprises at least one binder.
The panel may further comprise at least one top layer. The top layer is usually provided on the top surface of the panel. Advantageously, the top layer has properties suitable for its intended use, such as a water barrier layer, an abrasion resistant layer and/or a decorative layer. The top layer may be attached directly or indirectly to the core layer of the panel, e.g. via an adhesive, a hot melt material and/or hot or cold pressing. If a decorative top layer is applied, it may for example comprise at least one cellulose-based layer, preferably paper or kraft paper, and a cured resin. The layer of cellulose-based material may also be a veneer layer adhered to the top surface of the core layer. The veneer layer is preferably selected from wood veneer, cork veneer, bamboo veneer, and the like. Other decorative top layers that may be applied to the present invention include ceramic tiles or tiles, real stone sheets, rubber sheets, decorative plastic or vinyl, linoleum and decorative thermoplastic films or foils. Possibly, the top layer may further be provided with a wear resistant layer and an optional coating. Examples of thermoplastics that can be used in such top layer are PP, PET, PVC, etc. An optional primer may also be provided on the upwardly facing surface of the core and the desired visual effect printed in a direct printing process. The decorative top layer may be further finished with a thermosetting varnish or lacquer, such as polyurethane, PUR or melamine based resins.
In another possible embodiment, the panel comprises at least one backing layer. This may be any suitable backing layer for use with (floor) panels. It is also conceivable that the panel comprises (at its back side) at least one balancing layer, which typically consists of at least one layer comprising lignocellulose and a cured resin. The panel may also comprise at least one acoustic layer, which typically consists of a low-density foam layer of Ethylene Vinyl Acetate (EVA), radiation cross-linked polyethylene (IXPE), expanded polypropylene (XPP), expanded polystyrene (XPS), but which may also be a non-woven fibre, for example made of natural fibres (such as hemp or cork) or recycled/recyclable materials (such as PET). The density of the acoustic layer is preferably 65kg/m3To 300kg/m3And most preferably 80kg/m3To 150kg/m3In the meantime.
The invention also relates to a floor covering comprising a plurality of panels, in particular floor panels, according to any of the preceding claims. However, wall coverings comprising a plurality of panels according to the invention also fall within the scope of the invention.
Drawings
The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures. In the drawings:
figure 1 is a first possible embodiment of a panel according to the invention;
figure 2 is a second possible embodiment of a panel according to the invention; and
fig. 3 is a third possible embodiment of a panel according to the invention.
Detailed Description
Figure 1 shows a schematic view of a cross-section of a first embodiment of a panel 101 according to the invention. The figure shows a panel 101 comprising a core layer 102, the core layer 102 comprising magnesium oxysulfate whiskers 103 at least partially forming a crystalline structure 104. It can be seen that the magnesium oxysulfate whiskers 103 interlock with each other. The panel 101 further comprises a top layer 105 and optionally a backing layer 106.
Fig. 2 shows a schematic view of a cross-section of a second possible embodiment of a panel 201 according to the invention. The figure shows a panel comprising: a core layer 202 comprising an upper portion 202a and a lower portion 202 b; and a reinforcement layer 207, the reinforcement layer 207 being located between said upper portion 202a and said lower portion 202b of the core layer 202. Both portions 202a, 202b of the core layer 202 comprise magnesium oxysulfate whiskers 203 at least partially forming a crystalline structure 204. It can be seen that only a portion of the total volume of the core layer 202 includes the crystalline structure 204. The reinforcing layer 207 includes a glass fiber mesh. The panel 201 also includes a top layer 205.
Figure 3 shows a schematic view of a cross-section of a third possible embodiment of a panel 301 according to the invention. The figure shows a panel comprising a core 302, wherein the core 302 comprises an upper portion 302a, a lower portion 302b and a middle portion 302c, respectively. These portions are separated by a plurality of reinforcing layers 307a, 307 b. In this embodiment, the central portion 302c of the core layer 302 is a foam layer. Other portions 302a, 302b of the core layer 102 include magnesium oxysulfate whiskers 303, the magnesium oxysulfate whiskers 303 at least partially forming a crystalline structure 304. The panel 301 also includes a top layer 305.
It is obvious that the invention is not limited to the embodiments shown and described herein, but that within the scope of the appended claims many variations are possible which are obvious to a person skilled in the art.
The verb "to comprise" and its conjugations used in this patent disclosure is understood to mean not only "comprising" but also the phrases "comprising", "consisting essentially of … …", "formed of … …" and its conjugations.

Claims (19)

1. Panel suitable for forming a floor covering, in particular a floor panel, wherein the panel has a substantially flat top side and a substantially flat bottom side, and at least four substantially linear side edges comprising at least one pair of opposite side edges,
the panel includes:
at least one core layer comprising, at least in part, a magnesium crystal structure,
wherein the at least one core layer comprises 0.05 to 5 weight percent of at least one organic compound comprising at least two hydroxyl groups.
2. Panel according to claim 1, wherein the magnesium crystal structure is a magnesium oxysulfate and/or magnesium oxychloride crystal structure.
3. Panel according to any one of the preceding claims, wherein at least a part of the magnesium crystals are present as long interlocking crystal structures or "whiskers" and some of the magnesium crystals are present as short irregular crystal structures or "flakes".
4. Panel according to any one of the preceding claims, wherein the ratio of whisker phase to lamellar crystal phase is higher than 1.
5. Panel according to any one of the preceding claims, wherein at least a plurality of magnesium crystals have an aspect ratio of at least 5, preferably at least 10, more preferably at least 20.
6. Panel according to any one of the preceding claims, wherein at least a plurality of magnesium oxysulfate crystals, in particular magnesium oxysulfate whiskers, has an average diameter in the range of 0.2 to 1.0 micrometer.
7. Panel according to any one of the preceding claims, wherein at least a plurality of magnesium oxysulfate crystals, in particular magnesium oxysulfate whiskers, have an average length in the range of 1 to 50 micrometers.
8. Panel according to any one of the preceding claims, wherein the core layer comprises at least 5 wt% magnesium oxysulfate whiskers, preferably at least 10 wt%, more preferably at least 20 wt% of a whisker phase crystal structure.
9. Panel according to any one of the preceding claims, wherein the organic compound comprising at least two hydroxyl groups (-OH) is an acid, such as oxalic acid, citric acid, phosphoric acid, boric acid.
10. Panel according to any one of the preceding claims, wherein the core layer comprises an upper portion and a lower portion and a reinforcement layer between the upper portion and the lower portion of the core layer.
11. The panel according to claim 10, wherein the reinforcing layer comprises fiberglass.
12. Panel according to any one of claims 10 to 11, wherein the upper reinforcing layer comprises a glass fibre mesh.
13. Panel according to any one of claims 10 to 12, wherein the core layer comprises a middle portion and a further reinforcement layer, wherein a first reinforcement layer is located between the upper portion and the middle portion of the core layer and a second reinforcement layer is located between the middle portion and the lower portion of the core layer.
14. Panel according to one of the foregoing claims, comprising two pairs of opposite side edges provided with interconnected coupling means.
15. Panel according to any one of the preceding claims, wherein the interconnected coupling means comprise a tongue and a groove, wherein the tongue is provided on one of a pair of opposite side edges and the groove is provided on the other of the same pair of opposite side edges.
16. Panel according to any one of the preceding claims, wherein the core layer further comprises at least one binder.
17. Panel according to any one of the preceding claims, comprising at least one top layer, which top layer comprises at least one decorative layer and/or protective layer.
18. Panel according to any one of the preceding claims, comprising at least one optional backing layer for improving balance and/or acoustic properties.
19. Floor covering comprising a plurality of panels, in particular floor panels, according to any of the preceding claims.
CN202010661689.8A 2020-01-31 2020-07-10 Panel for forming a floor covering and such a floor covering Pending CN113202253A (en)

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